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Message: <blockquote data-quote="Still Afloat" data-source="post: 510865" data-attributes="member: 32426">I can see a few problems with this concept:1. Will the working time of the pour foam allow adequate time to set the deck?2. The weight of the two aluminum sheets combined is excessive.  One sheet of less total thickness would be strong enough.  3.  How will you remove the deck in the event that the hull needs service?If you are really trying to get the best fit from the foam sheets, you may want to consider building or buying a hot wire foam cutter.  The foam could be cut in a rib fashion and laminated. This would provide a tight fit for maximum floatation  and deck support.</blockquote>